Metal Working|A blog about metal working as a hobby.
Aug
13
Filed Under (Art) by Michael
Kent Kelin asked:
Metal casting is an ancient technique that has a variety of applications and purposes. Civilizations from the dawn of time to present day have used metal working as a way of creating artistic, religious, and practical items. The process of metal casting involves melting metals at high temperatures and using molds to then shape the metal into new items. The furnaces used in metal casting helped pave the way for the Industrial Revolution, without which the course of history would be dramatically different. Metal casting is just one form of metal working that has seen a recent surge in popularity as resources are becoming more affordable and communities are springing up to share information, ideas, and projects.
Metal casting requires specialized equipment, knowledge, and some creativity. While metal casting is used on an Industrial level as the process cuts cost and proves to be highly efficient, many individuals participate in metal casting as a hobby and in artistic endeavors. Many people are drawn to metal casting for one reason or another, although there seems to be two main motivations that stand out. The first motivation that brings hobbyists to practice metal casting is need; people may need to create items or parts for other ventures. Metal casting is a great way to build hard to find pieces for models, restoration projects, and even just small replacement parts needed for common household items. The second motivation for using metal casting is using it as a way to create sculptures or other artistic endeavors.
Whatever the reason, small scale metal casting is attractive because that it can be done right at home, either in the backyard or workshop. Individuals working in metal casting are able to create home made tools and equipment like furnaces and molds. Metal casting is only limited by the individual’s desire, so for those with the time and the need, virtually anything is possible.
The actual casting process in metal casting has several forms, the most popular being sand casting. Sand casting involves creating a mold from sand which can be created at home, and then pouring the liquid metal into the mold. Afterwards, the metal is allowed to air dry and the mold is removed. This type of casting proves to be the most economical, but other types of casting can provide fuller detail and higher quality results.
Since metal casting involves working with metal in its molten form, the process can be dangerous if undertaken by the reckless or ill informed. The melting points of several metals are well above 1,000 degrees Fahrenheit, or 530 degrees Celsius. It is vital that anyone wanting to work with metal casting take all the proper precautions. Safety advice can range from simple common sense such as “never look directly into a high powered flame” to more specific warnings such as “when molten metal contacts a nonporous surface with water it is liable to explode, splashing hot metal everywhere.” The use of appropriate safety gear such as gloves and goggles is necessary as well.
With time, dedication, and some know how, anyone can practice the craft of metal casting. Metal Casting is a very enjoyable and rewarding craft but it does require a certain amount of education to get started.
Metal casting is an ancient technique that has a variety of applications and purposes. Civilizations from the dawn of time to present day have used metal working as a way of creating artistic, religious, and practical items. The process of metal casting involves melting metals at high temperatures and using molds to then shape the metal into new items. The furnaces used in metal casting helped pave the way for the Industrial Revolution, without which the course of history would be dramatically different. Metal casting is just one form of metal working that has seen a recent surge in popularity as resources are becoming more affordable and communities are springing up to share information, ideas, and projects.
Metal casting requires specialized equipment, knowledge, and some creativity. While metal casting is used on an Industrial level as the process cuts cost and proves to be highly efficient, many individuals participate in metal casting as a hobby and in artistic endeavors. Many people are drawn to metal casting for one reason or another, although there seems to be two main motivations that stand out. The first motivation that brings hobbyists to practice metal casting is need; people may need to create items or parts for other ventures. Metal casting is a great way to build hard to find pieces for models, restoration projects, and even just small replacement parts needed for common household items. The second motivation for using metal casting is using it as a way to create sculptures or other artistic endeavors.
Whatever the reason, small scale metal casting is attractive because that it can be done right at home, either in the backyard or workshop. Individuals working in metal casting are able to create home made tools and equipment like furnaces and molds. Metal casting is only limited by the individual’s desire, so for those with the time and the need, virtually anything is possible.
The actual casting process in metal casting has several forms, the most popular being sand casting. Sand casting involves creating a mold from sand which can be created at home, and then pouring the liquid metal into the mold. Afterwards, the metal is allowed to air dry and the mold is removed. This type of casting proves to be the most economical, but other types of casting can provide fuller detail and higher quality results.
Since metal casting involves working with metal in its molten form, the process can be dangerous if undertaken by the reckless or ill informed. The melting points of several metals are well above 1,000 degrees Fahrenheit, or 530 degrees Celsius. It is vital that anyone wanting to work with metal casting take all the proper precautions. Safety advice can range from simple common sense such as “never look directly into a high powered flame” to more specific warnings such as “when molten metal contacts a nonporous surface with water it is liable to explode, splashing hot metal everywhere.” The use of appropriate safety gear such as gloves and goggles is necessary as well.
With time, dedication, and some know how, anyone can practice the craft of metal casting. Metal Casting is a very enjoyable and rewarding craft but it does require a certain amount of education to get started.
Aug
07
Filed Under (Art) by Michael
Kent Kelin asked:
Metal casting supplies can run the gamut of cheap to expensive. Home foundries tend to use supplies that are not too costly or that can be found close at hand. After all, home metal casting is usually a hobby and many get into this hobby since they need a cheaper source of parts and pieces that are either far too expensive or just impossible to find. This reason is actually what draws many people to metal casting in the first place. Given this, metal casting supplies used in smaller backyard foundries are generally cheap and made of items that are available in the garage or can be found at home improvement stores. There are several online resources and stores that offer supplies specially made for metal casting and if you have the money and are unable to create your own, it is encouraged that you purchase already made supplies.
The metal casting supplies you will need ultimately depend upon the type of work you plan to do. If you plan to use lost foam casting you will not need any wax and in that same thought you won’t need any foam if you are going to use lost wax casting. The furnace type is also a consideration. Cupola furnaces do not use crucibles. A crucible is where you place the metal which will then pool and collect inside. So it is important to decide what kind of casting process and what kind of furnace that will be used before you rush out to buy supplies.
As for the supplies this will include the fuel source. Fuels sources can range from wood to propane. Metals with a higher melting point will need propane while wood can be used to melt pewter and possibly aluminum. Most home foundries will use propane since it produces a high temperature and is easily available.
Many of the metal casting processes use sand as a way to create molds and help secure those molds during the pouring. The type of sand used does not have to necessarily be specially formulated. Sand has been used in casting since ancient times so it only makes sense that most sand types can be used. Many hobbyists will even use playground sand to meet their needs. Now, there is a special type of sand used in casting called green sand. Green sand packs well and is able to hold its shape far better then common sand. For processes like lost wax you will need to find a healthy supply of wax since many of the steps involve the creation of wax models and molds. The good thing about this process is that the wax can be reused time and time again. Supplies for lost foam can be found in home improvement stores since foam insulation is suitable to use. You will not be able to reuse the foam but luckily, the foam is cheap.
Perhaps the most important casting supply is the metal itself. The metal used in casting varies due to need. Aluminum is a common alloy used in casting for a number of reasons, chief among them is availability. Aluminum soda cans are crushed and melted and proves to a good source of the metal. Many casters will find scrap metal in junk yards which tend to be a good source for brass, bronze, and iron. There are places to buy metals in ingots if you want a purer metal to work with.
Metal casting supplies often dictate what the caster can and can not do. Keep this in mind as you plan your next project as adjustments might be needed to your plan.
Metal casting supplies can run the gamut of cheap to expensive. Home foundries tend to use supplies that are not too costly or that can be found close at hand. After all, home metal casting is usually a hobby and many get into this hobby since they need a cheaper source of parts and pieces that are either far too expensive or just impossible to find. This reason is actually what draws many people to metal casting in the first place. Given this, metal casting supplies used in smaller backyard foundries are generally cheap and made of items that are available in the garage or can be found at home improvement stores. There are several online resources and stores that offer supplies specially made for metal casting and if you have the money and are unable to create your own, it is encouraged that you purchase already made supplies.
The metal casting supplies you will need ultimately depend upon the type of work you plan to do. If you plan to use lost foam casting you will not need any wax and in that same thought you won’t need any foam if you are going to use lost wax casting. The furnace type is also a consideration. Cupola furnaces do not use crucibles. A crucible is where you place the metal which will then pool and collect inside. So it is important to decide what kind of casting process and what kind of furnace that will be used before you rush out to buy supplies.
As for the supplies this will include the fuel source. Fuels sources can range from wood to propane. Metals with a higher melting point will need propane while wood can be used to melt pewter and possibly aluminum. Most home foundries will use propane since it produces a high temperature and is easily available.
Many of the metal casting processes use sand as a way to create molds and help secure those molds during the pouring. The type of sand used does not have to necessarily be specially formulated. Sand has been used in casting since ancient times so it only makes sense that most sand types can be used. Many hobbyists will even use playground sand to meet their needs. Now, there is a special type of sand used in casting called green sand. Green sand packs well and is able to hold its shape far better then common sand. For processes like lost wax you will need to find a healthy supply of wax since many of the steps involve the creation of wax models and molds. The good thing about this process is that the wax can be reused time and time again. Supplies for lost foam can be found in home improvement stores since foam insulation is suitable to use. You will not be able to reuse the foam but luckily, the foam is cheap.
Perhaps the most important casting supply is the metal itself. The metal used in casting varies due to need. Aluminum is a common alloy used in casting for a number of reasons, chief among them is availability. Aluminum soda cans are crushed and melted and proves to a good source of the metal. Many casters will find scrap metal in junk yards which tend to be a good source for brass, bronze, and iron. There are places to buy metals in ingots if you want a purer metal to work with.
Metal casting supplies often dictate what the caster can and can not do. Keep this in mind as you plan your next project as adjustments might be needed to your plan.
Aug
05
Filed Under (Art) by Michael
Kent Kelin asked:
The most noticeable item in any backyard foundry is the furnace. This is no surprise really, because without the furnace the entire metal casting operation would be nonexistent. The furnace can take really any size and form depending upon the need and budget of the metal caster. What really makes home metal casting furnaces really unique is how many of them come into creation.
Sure there are plenty of companies that will gladly sell furnaces for the hobby metal caster and while this can be a viable solution to your furnace needs many metal casters prefer another method.
Making your own furnace is not as far fetched as it may seem and if you already a Do It Yourselfer, chances are you will have the needed skills and tools in your workshop or garage already. There are a variety of reasons why people make their own furnaces. The most common reason is fulfilling a need.
Many hobbyist and metal workers find out, to their dismay, that the local commercial foundries can not make the needed part or if they do, they feel the need to charge an outrageous sum. Not to mention the fact that the traditional methods of metal casting is quickly becoming forgotten as the industry turns to electric furnaces. So many hobbyists find that constructing their own furnace is an absolute necessity and a great way to preserve a piece of craftsman history. The artisans who use metal casting to create sculptures and other pieces find that making their own furnace grants them a greater amount of control over the entire process. This is actually how many people get into metal casting to begin with.
Most likely, your first furnace is going to be a small and rather simple one. There is really no need to run before you can walk when it comes to something that will be using intense heat and melting iron which can be rather dangerous.
Home made furnaces have been constructed from coffee cans to trash cans or sheet metal welded together. While there are a few components that really should be bought like the retractor to line the furnace walls which should be resistant to high temperature for a prolonged period of time along with special connectors and regulators, most of the furnace can be created in your own home. You should be able to find most of the components that you can not make at hardware stores or plumbing supply stores for relatively cheap.
Along with the furnace parts you will also need to buy a crucible which will hold the metal as it melts along with the appropriate tools that you will use to handle the crucible. While you are at it you might as well buy all the safety equipment like gloves, protective eye wear, and leather shoes. There is other safety equipment that you will need depending on the type of work and the type of furnace you are going to make.
Most likely, your first furnace is going to be a simple cupola variation. The cupola furnace which is going to resemble a smoke stack is a simple design and is relatively easy to make for anyone with mild craft skill. This type of furnace will not require a crucible since you will be able to pour the molten metal from the furnace itself into a ladle that can then be poured into the mold.
DIY casting furnaces are a great way to connect yourself with your metal casting work giving you more control. While building the furnace can be complicated at first, once you delve into it you will find the experience enjoyable and fascinating.
The most noticeable item in any backyard foundry is the furnace. This is no surprise really, because without the furnace the entire metal casting operation would be nonexistent. The furnace can take really any size and form depending upon the need and budget of the metal caster. What really makes home metal casting furnaces really unique is how many of them come into creation.
Sure there are plenty of companies that will gladly sell furnaces for the hobby metal caster and while this can be a viable solution to your furnace needs many metal casters prefer another method.
Making your own furnace is not as far fetched as it may seem and if you already a Do It Yourselfer, chances are you will have the needed skills and tools in your workshop or garage already. There are a variety of reasons why people make their own furnaces. The most common reason is fulfilling a need.
Many hobbyist and metal workers find out, to their dismay, that the local commercial foundries can not make the needed part or if they do, they feel the need to charge an outrageous sum. Not to mention the fact that the traditional methods of metal casting is quickly becoming forgotten as the industry turns to electric furnaces. So many hobbyists find that constructing their own furnace is an absolute necessity and a great way to preserve a piece of craftsman history. The artisans who use metal casting to create sculptures and other pieces find that making their own furnace grants them a greater amount of control over the entire process. This is actually how many people get into metal casting to begin with.
Most likely, your first furnace is going to be a small and rather simple one. There is really no need to run before you can walk when it comes to something that will be using intense heat and melting iron which can be rather dangerous.
Home made furnaces have been constructed from coffee cans to trash cans or sheet metal welded together. While there are a few components that really should be bought like the retractor to line the furnace walls which should be resistant to high temperature for a prolonged period of time along with special connectors and regulators, most of the furnace can be created in your own home. You should be able to find most of the components that you can not make at hardware stores or plumbing supply stores for relatively cheap.
Along with the furnace parts you will also need to buy a crucible which will hold the metal as it melts along with the appropriate tools that you will use to handle the crucible. While you are at it you might as well buy all the safety equipment like gloves, protective eye wear, and leather shoes. There is other safety equipment that you will need depending on the type of work and the type of furnace you are going to make.
Most likely, your first furnace is going to be a simple cupola variation. The cupola furnace which is going to resemble a smoke stack is a simple design and is relatively easy to make for anyone with mild craft skill. This type of furnace will not require a crucible since you will be able to pour the molten metal from the furnace itself into a ladle that can then be poured into the mold.
DIY casting furnaces are a great way to connect yourself with your metal casting work giving you more control. While building the furnace can be complicated at first, once you delve into it you will find the experience enjoyable and fascinating.
